2010-2011 Hydrogen Student Design Contest:

2010-2011 Hydrogen Student Design Contest: Residential Fueling with Hydrogen

Design report

University of Bridgeport

Team members:

Xu Yang

Pei-yuan Hsu

Joshua L. Dibia

Faculty advisor:

Linfeng Zhang

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University of Bridgeport, 126 Park Avenue, Bridgeport, CT 06604 USA

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Executive summary

Pollution and emission from fossil fuel already become a serious environmental issue. To

solve this problem, more and more green energy or renewable energy has been used into and

impact onto modern society. For instance, solar energy, hydrogen resource, and wind turbine

gradually playing most important role in manufactory industry. Scientists, governments and

activist groups have been advocating alternative fuels for decades. Hydrogen as a energy

carrier become our best choice since it is abundant in the nature, totally clean, low cost, and

renewable.

Even though there are several advantages of hydrogen, the drawbacks of the hydrogen can

not be omitted. For instance, hydrogen is not an energy source. It does not occur in nature in

its elemental or molecular form. Therefore, hydrogen must be produced. This design is to

produce hydrogen for the hydrogen cars belonged to the residents of Bodine Hall, a

dormitory at the University of Bridgeport, through a solar energy powered system. In this

design, a Proton-Exchange-Membrane (PEM) eletrolyzer is used as a hydrogen generator,

solar panels are used to convert solar energy to electricity for electrolyzer, and a hydrogen

compressor is used to compress hydrogen.

Solar panel is the source of free and clean electricity for a solar generator. The PV or solar

panel does the function of converting sunlight into DC (Direct Current) electricity.

A stand-alone photovoltaic system is an independent solar energy system that is off grid. In

this context, a stand-alone Photovoltaic system is designed to supply clean electricity to the

electrolyzer which functions to produce hydrogen from water. The end result of the process

results in fueling the residential Bodine hall with hydrogen.

Although several methods have been and are being developed to generate hydrogen with

renewable energy resources, the only one currently practical is water electrolysis.

Electrolyzer is a well known way to split water (H2O) into hydrogen and oxygen by

electricity and It is the opposite of a fuel cell. Most of the electrolyzers used today in

capacities up to several thousand m3/h are based on alkaline (KOH) electrolyte. For instance,

marina always work as a big electrolyzer, it electrolyze sea water to obtain hydrogen and then

store hydrogen in order to supply it to some hydrogen powered ship later. Another option is to

use a proton exchange membrane as electrolyte and this kind of electrolyzer will be further

discussed in this design. Moreover, hydrogen storage is important in this design and a ,

dispenser is also necessary , to link the whole system to the hydrogen car.



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Table of contents

1 Technical design ....................................................................................................................................3

1.1 Principle and fundamental ....................................................................................................3

1.1.1 Solar panel system.........................................................................................................3

1.1.2 Electrolyzer system .......................................................................................................4

1.1.3 Compressor system .......................................................................................................5

1.1.4 Tank and dispenser system...........................................................................................7

1.2 Mathematics model ................................................................................................................7

1.2.1 Fundamental of the PV system ....................................................................................8

1.2.2 Electrolyzer....................................................................................................................9

1.2.3 Compressor..................................................................................................................10

1.2.4 Simulation result .........................................................................................................11

1.3 Site plan.................................................................................................................................12

1.3.1 Site location..................................................................................................................12

1.3.2 Residential building model .........................................................................................12

1.3.3 Equipment site.............................................................................................................13

1.4 Major component .................................................................................................................15

1.4.1 Hydrogen tank .............................................................................................................15

1.4.2 Electrolyzer..................................................................................................................15

1.4.3 Compressor..................................................................................................................16

1.4.4 Dispenser......................................................................................................................17

1.4.5 Solar panel ...................................................................................................................18

1.4.6 Conclusion for technical design .................................................................................19

2 Safety analysis .....................................................................................................................................19

2.1 Unpredictable safety hazards ..............................................................................................19

2.2 Predictable safety hazards...................................................................................................19

2.3 Code and standard ...............................................................................................................20

2.4 Safety recommend ................................................................................................................21

3 Environment Analysis.........................................................................................................................21

3.1 Solar Panel carbon dioxide emissions.................................................................................21

3.2 MIT study .............................................................................................................................22

4 Economic Analysis: .............................................................................................................................23

4.1 Total cost ...............................................................................................................................23

4.2 Comparison...........................................................................................................................25

5 Marketing and Education plan..........................................................................................................26

5.1 Marketing plan .....................................................................................................................26

5.2 Education Plan .....................................................................................................................26

6 Appendix..............................................................................................................................................28



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1 Technical design

For years, after hundreds of scientists and researchers untiringly hard work in the new energy

field, hydrogen powered technologies have been improved and upgraded. However, this kind

of technology has not been well used in civil industry. Our project is focused on solving this

kind of issue to design a system to supply hydrogen to common residential building and

hydrogen car.

1.1 Principle and fundamental

1.1.1 Solar panel system

The photovoltaic (PV) solar cells convert sunlight directly into electricity. The PV cell

consists of two or more layers of semi-conducting material, mostly the silicon. When it is

exposed to light, holes and electrons are produced to go through the external circuit as Direct

Current (DC).The PV system works effectively when the sun is shinning and more electricity

is produced when the sunlight is very strong and strikes the PV cells directly.

Figure. 1 Solar panel system

Schematic of the PV system

Figure. 2 Schematic diagram showing the supply of solar power to the electrolyzer system.



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Some losses

When designing and installing a solar-based renewable energy system, it is very important to

consider about the losses. This means accounting for, and minimizing, losses associated with

a variety of system components. For our design, there are some major losses affect our

system and lead to the low efficiency of the system. Looses affect PV system are calculated

by

Losstotal=Lossinverter x Lossohmic x Losstemperature x Lossfundamental x Lossdynamic

The total loss we can obtain from a two years long project about PV system which located in

Dutch. Through that report, we can find out the performance ratio is 0.612. This ratio you can

find out from appendix.

1.1.2 Electrolyzer system

Flow chart

Chart. 1 Flow chart of electrolyzer system

Structure of electrolyzer

Voltage

regulator

Electrolyzer

stack

Water

supply/pump

Drying

unit

Solar

panel

Storage



5

Figure. 3 PEM electrolyzer structure [1]

Figure. 4 PEM fuel cell model [11]

The structure of a PEM based electrolyzer is shown in Figure 3. The oxygen will be expelled

from the anode and the hydrogen is generated on the cathode. The problem within this system

is that the hydrogen is saturated with water vapor Figure 4 is a single PEM electrolyzer which

will be used, it is just a model we use to simulate and analysis, if we want to use PEM

electrolyzer in practical, an electrolyzer stack would be a good choice and lots of practical

problems like heat removal should be considered.

Basic fundamentals

At the negative electrode, protons are removed from the electrolyte, electrons are provided by

the external electrical supply and hydrogen is formed via the reaction:

4H+ + 4e- 2H2

At the positive electrode, the water is oxidized (electrons removed) and oxygen is made via

the reaction:

2H2O O2 + 4H+ + 4e-

Key advantages

• The product hydrogen is very pure.

• It is produced as needed and does not have to be stored, and so is safer.

• Electricity is much easier and safer to supply than bottled hydrogen.

• The marginal cost is only a few cents per kilogram – much cheaper than gas supplied

in high-pressure cylinders.

1.1.3 Compressor system

Working flow chart



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Chart. 2 Flow chart of compressor

In Chart 2, the gas is collected from electrolyzer, and then is delivered to the compressor to

increase the gas pressure, after this process, tank is used to storage gas. When a hydrogen car

comes to the dispensing station, hydrogen will be gassed up by the dispenser.

Compressor working principle

Figure. 5 Centrifugal or radial type compressor

In figure 5, this kind of compressor is called centrifugal or radial type compressor. This is the

common type in the market. The gas is drawn in the center and flung out in high speed to the

outer volute. So the kinetic is converted to a pressure increase. And then, this pressure

increase will become the high pressure gas. After that, it can get the high pressure gas that we

need at the output of the centrifugal type compressor [1].



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Figure. 6 Typical centrifugal air compressor rotor

In figure 6, this is the rotor of centrifugal. The central of the rotor is not very straight, because

it can increase the pressure more than straight rotor. And the major beneficial of centrifugal

compressor are the low cost and technique well developed. That is the reason why centrifugal

compressor is the common type in the market [1].

1.1.4 Tank and dispenser system

Figure.7 Tank and dispenser working flow chart

In Figure 7, hydrogen is stored in tank after it compressed in the compressor unit. (The

storage capacity of a tank is 250L). A PLC control unit is used to not only automatically

operate but also protect the system: The system will produce the hydrogen automatically if

the hydrogen is less than 200L; The system will stop if the hydrogen is more than 240L. In

addition, the PLC control unit can control the dispenser nozzle equipment to make sure the

nozzle is already connected to the vehicle before fueling hydrogen [2].

1.2 Mathematics model

Before build up the whole system, a mathematics model is set up to simulate the working

process of the system. To simplify the model, each parameter is under experiment level which

means its value in the mathematics model is not in the same order of magnitude. All the data



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comes from the common knowledge and journals.

1.2.1 Fundamental of the PV system

Efficiency of PV system

According to the Dutch’s PV system report, the efficiency of a PV system is about 0.612.

Fundamentals of PV system

Specification of the PV :

300 W Mono Crystalline Silicon Cell module

Area of each module = 1.5m x 2m = 3m2.

Connection type : Series

The following are the basic fundamental equations applied:

Power (watts) = Energy (Joules) / Time (seconds)

Power = (Area of solar panels in m2) x 300 watts/m2

Considering the DNI zip-code solar insolation time calculator which is based on data

provided by NASA, Bridgeport has an average daily insolation of 4.2 hours with Latitude of

41.1 and Longitude of -73.2. Therefore, the Sunlight shines in the same location for 4.2 hours

per day [16]

Figure. 8 Insolation Hours

The length of time solar radiation hits the solar panel(s) must be added:

Power = (Area of solar panels in m2) x 300 watts/m2 x (Insolation time)

Therefore, with the above mathematical model, the amount of solar panel area and/or

electricity produced is being determined, considering the following:

Power rating of each panel = 300Watts

Area of one (1) panel = 2m x 1.5m = 3.0 meter square

Considering one panel:

Power = (3.0m2) * 300 Watts/m2 * 4.2 = 3780 Watts/day



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Consider about the efficiency, the power supply for one panel in one day is:

3780 x 0.612 =2313.36 watts/day = 2.31 KW/day

1.2.2 Electrolyzer

Reversible potential

The reversible potential is the voltage of the electrolyzer without losses

Since:

Where F is a constant 96485 coulombs, and Δgf we can find out from the following Table 1:

Table. 1 Gibbs free energy for the reaction H2 + 1/2O2 → H2O [1]

Over potential

The main over potentials of an electrolyzer are the activation over potential, ohmic over

potential, and concentration over potential. Since the concentration over potential can be

omitted by working in a low current situation which is the working environment of the

mathematics model, in our paper, we just consider about ohmic over potential and activation

over potential.

[1]

The activation overpotential is caused by the slowness of the reactions that take place at the

electrodes surface

[11]

The ohmic overpotential is due to the resistance to flow of electrons through the electrodes

(electronic resistance) and the resistance to flow of ions through the membrane electrolyte

(protonic resistance)

[11]

Both activation and ohmic over potential equation are deduced from mathematics model

experiment which works in room temperature (25oC), 1atm, I<1.5A



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Hydrogen (H2 ) flow

We can easily understand that for the hydrogen electrolyzer, two electrons will pass through

the external circuit for each water molecule consumed and each molecule of hydrogen

produced.

Then we have: Charge per mole = -2eNa=-2F

Where e is elementary charge = 1.602*10-19 coulombs

Na is a constant = 6.022*1023

Therefore, we can find out the total charge is:

Where nH2 is the total amount of the hydrogen are produced

We divided both side of the equation by time, then we get hydrogen flow:

H2 flow = I/2F moles/s

I is the DC current from the external circuit. Multiplying the expression above by hydrogen

mass (2.02 x 10-3kg/mole): H2 flow = Ix10-8 kg/s = Ix6x10-7kg/min

1.2.3 Compressor

First step: We need to know the different of inlet pressure and outlet pressure (we know it

from the temperature, because when the pressure is changed, the temperature also will be

changed.) The function is the following:

γ is ratio of the specific heat capacities of the gas, CP/CV [1]

In this function theηc is

[1]

And then, we calculate the power as the following function

[1]

is rate of gas of flow. Put ΔT into the function above, we have

[1]

In fuel cell system case, we use the values of Cp is 1004 J Kg -1 K-1 and γ is 1.4

Hence, we can get result of the function is



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[1]

1.2.4 Simulation result

According to our mathematics model, we used LabVIEW software to simulate our design.

Through the result of simulation, we can easily find out the energy transmitted from solar

panel to the system and the hydrogen generated by electrolyzer is stored into fuel tank.

Figure. 9 Initial stage Figure. 10 Slope stage

(a) (b)

Figure. 11 Shift stage Figure. 12 Final stage



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From charts above, we can figure out the working process of the system. We can see Figure.

9 is the initial stage of the system. We set insolation time with 100 minutes and set solar panel

area with 3m2 as Figure 10 showed. In Figure 11 and 12, we can find out while the

electrolyzer works with the up limit current, even the power of the solar panel keep

increasing, the hydrogen flow will not increase but keep in a fixed value.

1.3 Site plan

1.3.1 Site location

This design aimed to build a hydrogen fueling system for a dormitory of University of

Bridgeport. This university is located in Connecticut which is a state of north America. The

location as following figure showed. [12]

Figure. 13 Location of UB

1.3.2 Residential building model

The building we choose is the biggest dormitory in University of Bridgeport. Also it is the

tallest one in that region. The reason we chose Bodine Hall not only because it’s superior

external appearance, but also because it’s large number of resident and it is a broad parking

lot.

From the Figure 14, we can easily find out the external appearance of the system. There is a

big parking lot which can contain 100 cars around Bodine Hall, the dispenser system is

located into this parking lots. On the top of the building, it has about 1256m2 top area can be

built up PV system. Hundreds solar panel can supply enough power to the system in the

building.



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Figure. 14 Bodine Hall model

1.3.3 Equipment site

From 1.3.2, we can know that PV system and dispensing system has already been

built outside of the building. The rest of the system equipment will be built in the basement of

Bodine Hall.



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Figure. 15 Basement of Bodine Hall

From figure 15, we have the plan of basement of Bodine hall. Everything was drawn

in the same proportion. Each equipment is drawn based on the dimension in the specification,

from the figure above, it is easy to figure out that the space of the basement totally big

enough to contain all the equipment. The dimension of the equipment will be list in the

appendix. Since Bodine Hall has great Ventilation system, the heat removal system would not

be a problem. Another problem can not be omitted is the noise. To solve this problem, we

build insulation layer and we setup the compressor to the green region which you can see in

Figure 15. There is lobby in the first floor just locate in the green region, so that even there is

some small noise, it will not interrupt resident’s rest upstairs.



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1.4 Major component

In this part, we are emphasizing on the practical design for the system. Before choosing

major component, there are several parameters we must take into account when developing

our design.

Table. 2 The hydrogen vehicle requirements

According to the Table 2 above, we can find out:

The annual mileage of a car Mannual=12,000 miles

The daily commute of a car Mdaily=35miles

The fuel mileage of a car Feco=44mile/kg

From section 1.3.2, we know that there are 100 parking lots around the Bodine Hall, we just

assume that there are 100 vehicles belong to the residents of this building. Therefore, we can

find out following information:

Monthly mileage of a car (Mmonth) is Mdailyx30days=1050miles/month

Then the monthly mileage of 100 cars is 105000miles/month

So that the H2 demand for 100 cars in one month is 105000/Feco=2386.36kg/month

According to all the data we assume, we can finish our design as following:

1.4.1 Hydrogen tank

The volume of each tank is 1000 liters. The monthly H2 demand for 100 cars is 34090.86

liters (liquid H2 density is 0.07kg/L) if we assume that each vehicle will be fuelled H2 4 times

per month. In this design, the maximum H2 demands for 100 cars on the same day is

8522.715 liters, therefore we must set up 8 hydrogen tanks [3].

1.4.2 Electrolyzer

In our design, we choose HOGEN S40 hydrogen generation system as our electrolyzer.

Specification of this equipment can be found in Table 3. Stack and complete packaged system

see Figure 16.

Hydrogen output 2.27 kg/24hr

Max delivery pressure 13.8 barg

Hydrogen purity (99.9995%) Water Vapor < 5 PPM

Max Consumption Rate 0.94 L/hr (0.25 gal/hr)

Water quality (min) required ASTM Type II Deionized Water required, < 1 micro



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Siemen/cm (>1 megOhm-cm)

Power consumption 6.7 kWh/ Nm3

Electrical supply required 205 to 240 VAC, single phase, 50 or 60 Hz

Operating environment In door

Dimensions 97 cm x 114 cm x 132 cm

Weight 650 lbs (295 kg)

Installation Plug & play

Controls and automation Fully aotumatic and unattended

Table. 3 Spec for electrolyzer

Figure. 16 HOGEN PEM Electrolyzer by Proton Energy Systems

As the totally H2 demand for 100 cars in one month is 2386.36kg/month, from the spec of our

equipment, we can calculate that each S40 monthly H2 supply is 68.1kg, therefore, we need

to setup at least 35 S40 systems to meet the demand. Hence the daily power demand for the

whole electrolyzer system (water circulation system, safety protection system, heat

removable system are included) is

6.7KWhm-3 x (2.27kg/24hr) /0.07kgL-1 x 24hrs x 35 = 182.5KW

So that electrolyzer system total daily power consumption is 182.5KW.

1.4.3 Compressor

There are many fuel cell station compressors on the market. However, a PPI Corporation’s

fuel cell station compressor is chosen because it meets our requirements.



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Figure. 17 PPI_HP3430 Fuel Cell Compressor

In a PPI fuel cell station compressor:

Hydrogen compressors to 15,000 psi (1000bar).

Hydrogen and other gases can do the requirement of leak tight pressure.

Leak tight compression.

Corrosion resistance.

Increased diaphragm life.

Low closure torque.

Highly sensitive leak detection [4]

The power supplied to a compressor can be calculated as:

[1]

Power = 1004 x (273+25)/0.6((25/0.1)0.286-1) x m x 24

Where, m = 2.27Kg/day x 35 / (60 x 60)=0.0009 Kg S-1

Then the power is 41.46KW/day.

In this compressor, there are a heat exchanger to remove heat and a safety control unit.

1.4.4 Dispenser

A hydrogen dispenser made by Censtar (Model: CS10J1110G model) is chosen in our design

due to its specification and price.

Figure.18 Censtar CS10J1110G hydrogen dispenser

The specification of the dispenser as the following:

Flow rate range:5 to 50 liter per minute

Noise: <80dB(A)

Power supply AC380V or AC220V with a changing

Motor’s out power: 750 W for vane pump an 1000 W for gear pump

Working environmental temperature:-40℃to +55℃

Relative humidity:30% to 90%

Horizontal distance from tank to dispenser < 15m

Vertical distance from tank to dispense pump < 4m [5]



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Since the H2 maximum demand per day is 8522.715 liters, we can find out the operation hour

is 8522.715/ 50 /60 = 2.83 Hours

Power = 1000W x 2.83Hrs = 2830 W =2.83 KW

Hence the dispenser maximum daily power consumption is 2.83KW.

1.4.5 Solar panel

Solar panels provide solar electricity from sunlight. They are typically made of silicon crystal

slices called cells, glass, a polymer backing, and aluminum frames. Solar panels can vary in

types and the size of a PV module refers to the panel’s rated output wattage. Solar panels with

12 or 24 Volts are generally preferred for off-grid systems with battery banks [17].

In this design, the Mono Crystalline silicon cell module is being used because of its high

efficiency compared to the other types of solar cell

Figure. 19 A typical home installed Figure. 20 A mono-crystalline silicon cell

with solar electricity

Specifications of the mono crystalline solar panel to be applied:

Power (max.) Pp: 300 watts

Voltage at maximum-power point Vp: 50.6 volts

Current at maximum-power point Ip: 5.9 amps

Open-circuit voltage Voc: 63.2 volts

Short-circuit current Isc: 6.5 amps

Dimensions (LxW): 1.5m x 2m [18]

Hence, for our design, we can find out from the site plan:

Total surface Area of Bodine building = 1256 m2

Area of one panel = 2m x 1.5m = 3m2

Therefore, Total number of panels = 1256m2 / 3m2 = 418.66. Giving room for tolerance, Total

panels = 410

Hence, if 1 panel generates 2.31 KW/day

410 panels will generate 410 * 2310 Watts/day = 947KW/day

A battery storage system is included in our system to store the spare power which



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generated from the PV system. Also this kind of system can supply power to the electrolyzer

even in overcast day. Battery sizing and tilt angle of the PV module are in the appendix.

1.4.6 Conclusion for technical design

From the design of this residential fueling system, it is obvious that this is a self

sufficient system. By using the PV power supply system, all the electricity demand of the

system can easily be met. The hydrogen which is generated by the electrolysis system will

totally supply enough power for the resident’s transportation. Since the power supply is more

than power demand, we can use the spare power into the daily utilities such as laundry room，

kitchen，illumination system.

2 Safety analysis

We are challenged to plan and design the basic elements of residential hydrogen fueling

system and installation. Therefore the safety of the residents who live in the selected building

is the big issue that must be considered. Since hydrogen is flammable over a wide range of

concentrations (above 4 vol%) and it’s ignition temperature is 500 oC, therefore any little

problem might result to disaster. The safety issue in our design can be divided into two

phases: unpredictable safety hazards and predictable safety hazards [13].

2.1 Unpredictable safety hazards

Since hydrogen is not easy to be stored, it will be dangerous if there is hydrogen leakage.

Some unpredictable factor may lead to hydrogen leakage and this will be taken into

consideration. For instance, natural disasters like earthquake and lighting strike will lead to

hydrogen leakage and explosion. Erosion would also be a serious problem since it may cause

hydrogen leakage. Even in such kind of issues, we can not predict, hence the risk that might

occur is really low. Therefore, we still need some procedure to lower the risk. For the above

mentioned issues, we can set up some alarm system in case of the leakage as well as the

lightning rod system on the roof to prevent lightning strike.

2.2 Predictable safety hazards

Since this kind of hazard we can predictable, let us have an adequate preparation to prevent

its occurrence. Hazards

issue

Causes Effect Freque-

-ncy

Solution

Fire

or

combustion

1.Static electricity

discharge

2.High

temperature

and pressure

3. Open flame

smoke

Fire

Combustion

Medium

Install anti-static electricity

system, temperature control

system, set up visible

warning sign to prevent

danger behavior like smoke



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Leakage 1. Piping/storage

corrosion

2. Unnatural

damage

3. Incorrect

manipulation

Asphyxia-

-tion

Combustion

Decrease

operating

pressure

High

Setup alarm system

Ventilation system

Using fully automatic

equipment to decrease

manual operation

Standardize operation

manual

Cryogenic

burns

1. Incorrect

manipulation

2. leakage

Get injured

Medium

Set up warning sign

Thermal insulation cover

Resident

faults

1. Resident’s

vehicle crash on

the dispenser

2. resident using

cell phone while

gassing up

Hydrogen

leakage

Combustion

Low

Set up barrier around the

dispenser

Warning sign and

concentration detector to

monitor the H2 leakage

Equipment

malfunc-

-tion

1. compressor

over load

2. pump cascade

control failure

Fire

System

breakdown

Low Every single component

has its safety prevent

system, if danger happens,

the whole system will be

shut down

Table. 4 Issue and solution

Table 4, above contains a detailed list of the hazard issues stated in our design. However,

some of the issues are not taken into account. If people intend to use this design in practical

project, every single hazard issue must be taken into account because detail is the key of

success. Both immature technology and unqualified operator are two major factors affect the

safety of the system. Most of the issue will be solved easily with the development of the

technology.

2.3 Code and standard

equipment Code & standard

All equipment AIAA G-095 , ISO TR 15916 , CGA Publication H4

Hydrogen generator CSA No. 5.99, ISO 22734-1 2008, ISO 16110-2, OSHA: 29

CFR 1910.103

Piping system NFPA 55, EIGA Doc 120/04,

Storage CGA Publication H6, NFPA 55 , CGA Publication PS17

Dispenser SAE J2799 - TIR, 20083235-T-469, 20083233-T-469

Detector ISA 12.13.01, ISO 26142

Table. 5 Code and standard [14]

All the equipments and parameters in our design are totally in keeping with code and

standard above. For the code and standard above, since we design a fueling system for the



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U.S. residential building, most of codes are America standard. As hydrogen and fuel cell

technology are getting improved, new safety challenges are expected to be discovered and

should be considered by some updated code and standard.

2.4 Safety recommend

Since most of the hazard issues will injure person, we must pay more attention on the system

even it’s a stable system. Here are some recommend:

a. Equipment daily maintenance

b. Operator monthly training

c. If danger arises, shut down the system immediately

d. Evacuate resident if necessary

e. Call 911

f. First aid for the wounded

g. The whole system will never be used until totally debug

3 Environment Analysis

In this society, the environment becomes the important issue for any countries. Especially the

gasoline, it is the most reason to destroyed the world rapidly, because the gasoline will

produce the carbon dioxide (CO2). It will make the average annual temperature increase, and

make our living environment becomes worst. Now there are many scientists around the world

want to find the solutions to solve it, and the fuel cell system using with hydrogen is the best

way to solve it. Hydrogen and fuel cell system is effective method can reduce the carbon

dioxide (CO2) from the gasoline.

3.1 Solar Panel carbon dioxide emissions

In this society, carbon dioxide makes the globe temperature increase. So lots of

researcher found the new renewable energy to instead of the gasoline energy to reduce the

carbon dioxide volume. In our system, we design the solar energy to supply our whole system.

Because solar energy is almost same as the hydrogen fuel cell energy, there are just a few

carbon dioxide emissions. The carbon emissions statistics by countries is as the following [6].

Chart 3. Carbon Emissions for Electricity Generation [6]



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About the statistics above the chart, using the coal and gasoline energies, the carbon

dioxide volumes is more than using renewable energy. It means using the renewable energy is

imperative act to rescue our living environment.

3.2 MIT study

According to the MIT study entitled “On the Road in 2020.” The fuel and vehicles [7]

Fuel and Vehicles

Technologies

Total Energy (MJ/km) Total GHG emitted (gC/km )

Gasoline ICE 2.34 47

Diesel ICE 1.77 37

Hybrid gasoline ICE 1.53 30

Hybrid CNG ICE 1.45 24

Hybrid gasoline Fuel cell 2.44 49

Hybrid hydrogen Fuel cell 1.69 34

Table. 6 Life -Cycle Energy Use and GHG Emissions for New Fuel and Vehicle Technologies

In Table 6, we can figure what the different of well – to – tank analysis of the greenhouse gas

(GHG) emissions for new fuel and vehicle technologies between the gasoline vehicles

technologies and hybrid hydrogen vehicles technologies. And according to those statistics, we

can understand the using the hydrogen system the total energy and total greenhouse gas

(GHG) are smaller than using the gasoline ICE (Internal Combustion Engine) system [7].

Forklifts system about the life – cycle energy use and GHG (greenhouse gas) emission

In many manufacture company, forklifts system is used regularly. And using hydrogen fuel

cell in forklifts system should be a tendency in the future. In this section, we search the

forklifts system using in ICE (Internal Combustion Engine), battery, and hydrogen fuel cell to

show the total energy usage and GHG (greenhouse gas) emission [8].

Figure. 21 Fuel cycle result of forklifts: Total Energy Use [8]

In above Figure, fuel cycle result of forklifts includes hydrogen materials of the



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recovery and transportation in energy usage, what the materials convert to the hydrogen fuel

cell, the hydrogen compressor, and using hydrogen on the forklifts in hydrogen fuel cell

system. For the ICE system, the total energy is used by recovery, transportation, and

processing in fuel cycle. It shows a high usage about the forklift in the ICE system. And

battery system, it also included the recovery, transportation, and processing in the fuel cycle,

but differently, the total energy using in batteries. Hence, the forklift for battery system is

fewer than ICE system [8].

Figure. 22 Fuel Cycle GHG Emissions for Forklift Technologies [8]

In Figure 22, it shows the fuel cycle GHG emissions for the forklift technologies. In

ICE system, the total energy also included recovery, transportation, and processing in fuel

cycle. And according to the figure, it tells us using ICE produced a high volume of fuel cycle

GHG emissions. In battery system, there are no any GHG emissions in this system. Because

the battery of GHG emissions’ gas is coke oven gas. The major ingredient of coke oven gas is

hydrogen. And about the hydrogen fuel cells, there are no any forklifts in fuel cycle GHG

emissions. Even if there are still upstream in this system, but the volume of the upstream is

still lower than battery and ICE system [8].

4 Economic Analysis:

The sunlight is free and abundant. The photovoltaic system allows you to generate

and store electricity in a battery bank for later use when needed. The Photovoltaic system

contributes to our energy security. Hence, it gives room for more job creation and also boosts

the economy. The Photovoltaic system also keeps us totally free from certain electricity

uncertainties and foreign oil dependence. This implies that it is an energy source which is free,

clean and highly reliable. It is also long lasting and has a life span of about 50 years and

requires little maintenance. Therefore, it presents a system that is capital intensive but cost

efficient in the long run.

4.1 Total cost

The economic analysis section includes capital cost for all equipments, installation

costs, training costs, repair costs, maintenance requirements costs, delivery costs, and



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operating costs. These equipments as below are needed in our design which is flexibility and

can help us to live up our idea in this hydrogen fuel cell design contest. The capital costs

shown as below in Table 7 (All of equipments do no include the tax.)

Item Quantity Cost (U.S. dollar)

1 Solar Panel system

1.1 Photovoltaic (PV) panel 410 $307,500

1.2 Battery 10 $6,000

1.3 Inverter 1 $275

1.4 Installation equipments(Wires…etc), Set up cost,

Training cost…etc

N/A $62,800

1.5 Safety equipments N/A $10,000

2 Electrolyzer System

2.1 PEM Hydrogen Electrolyzer 35 $700,000

2.2 Installation equipments(Including Delivery Pipe…etc),

Set up cost, Training cost…etc

N/A $140,000


3 Compressor System

(Include Storage Tank & Dispenser)

3.1 Hydrogen Compressor 1 $150,000

3.2 Hydrogen Storage Tank 8 $70,880

3.3 Dispenser Station 2 $30,000

3.4 Installation equipments(Including Delivery Pipe…etc),

Set up cost, Training cost…etc

N/A $50,200


Total $1, 550,655

Table. 7 The total cost of capital equipment summary [4,5]

In this chart, we follow the Economic Evaluation of Grid – Connected Fuel Cell Systems.

The installation equipments costs, set up costs, and training costs are 20 % off of the capital

equipments in each system [9].

Operating Cost:

In our design, operating cost is including water usage, operators, and maintenance. The

operating cost chart as the following: (All of operating cost do no include the tax.)

Water cost:

0.25 gallons x 24 hours x 35 = 210 gallons

1000 gallons = 6.025 dollars (Public Authority in Connecticut)

210 gallons x 365 days =76650 gallons / day



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76650 gallons / 1000 gallons = 76.65

76.65 x 6.025 = 461.82 dollars

Operator cost:

1 person x 100 dollars per day x 365 days = 36500 dollars

Maintenance cost:

Total equipments costs x 2% = 1550655 x 0.02 = 31013.1 dollars

Item Cost / year (U.S. dollar)

1 Water $461.82

2 Operators $36,500

3 Maintenance $31013.1

4 Electricity N/A(Solar energy)

Table. 8 Operating Cost per year [10]

In the Table 8 there is no any electricity costs, because in our design, we use the solar

energy to supply the whole system energy. Hence, we have no any electricity cost on our

design. About the maintenance fee that we calculated use 2 % off of the total capital

equipments costs. The operators’ fee that we think about one person’s salary is 100 dollars

daily. And the water usage cost, in Connecticut, 1000 gallons water usage in public authority

is 6.025 dollars, so that is reason why our water costs is lower [10].

The costs per kg of hydrogen productions that we calculated as the following

mathematics function:

Total capital equipment costs = 1550655

1550655 / 25 years life of machine = 62026.2 dollars / year

Total costs / month = {Total equipments costs + Operating costs (water + operators +

maintenance)}/ 12 = 10833.44 dollars /month.

And in our design, it can produce hydrogen 34090.86 liters = 2386.36 kg per month.

Hence, the hydrogen costs is 10833.44 / 2386.86 = 4.53 dollars / per kg.

In this section, we focus about the annual fuel costs for the hydrogen vehicle in 44

mile/kg compared to the annual fuel costs for conventional vehicle using gasoline with a fuel

economy of 32.6 miles per gallon. The simulation of those two energies is as following steps.

4.2 Comparison

Conventional vehicle:

Gasoline cost = 3.2 dollars per gallon / 32.6 miles per gallon = 0.098 dollars per mile



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Hydrogen vehicle:

Hydrogen cost = 4.53 dollars per kg / 44 miles per kg = 0.102 dollars per mile

Hence, the comparison chart of the hydrogen vehicle and the gasoline vehicle is shown as

below.

Category Cost / miles (U.S. dollars)

Hydrogen vehicle 0.102

Conventional vehicle 0.098

Table. 9 The cost comparison between hydrogen vehicle and conventional vehicle

5 Marketing and Education plan

As this technology blossoms, it is quite evident that so many opportunities will emerge as a

result of the concept of having residential fueling with hydrogen. The design of such system,

considering the Bodine hall as a proposed site would go a long way in making this concept a

reality. It might seem to be capital intensive but it is actually cost efficient in the long run.

A well detailed marketing strategy and education plan is basically what is needed to prove

beyond reasonable doubt that this system is quite feasible. The following strategies will be

applied by the University of Bridgeport team in actualizing this dream, creating awareness

and helping to educate the entire populate of Bridgeport and its environs.

5.1 Marketing plan

The University of Bridgeport team would like to create awareness about this

outstanding technology through out Bridgeport and its environs. This will be achieved

by driving hydrogen vehicles with very bold inscriptions through out the campus and

target areas around the entire city. By so doing, a lot of people will appreciate the

concept and embrace this new technology.

Have the University set up a well detailed website in conjunction with the state

government to create online advert. This will enable the government to be involved in

the process of creating more awareness to both residents of Bridgeport and residents.

Meet with interested local electrical engineering companies in order to promote this

new technology. Also working in partnership with these companies to physically

developing this technogy.

5.2 Education Plan

University of Bridgeport team would like to create awareness, beginning with making

the Fuel Cell course an interesting one. This can be achieved by embarking on series

of research and technical project geared towards promoting Fuel cell technology. A lot

of other students will be quite interested delve into it when they see their fellow

colleagues being embarked on such research projects.



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Review course policy and embark on massive training of students in this field. These

students should be made to embark on other developmental projects. This will help

introduce the concept of hydrogen as a fuel. It will also help the students to

understand the concept of Fuel Cell technology and its associated residential and

industrial applications.

The University of Bridgeport team is planning to create series of public workshops

where all staff and students will be invited at several intervals to learn about the new

concepts. More students will be encouraged to take up courses in Fuel cell, thereby

learning how the Fuel cell technology can use hydrogen and oxygen to create

electricity.

Creating a forum where students, professors and interested participants can meet to

educate and also discuss issues bordering around this technology. The meeting should

be publicized in order to give room for both students and non students to attend.



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6 Appendix

1. Some losses from Dutch’s report [15]

2. Battery Sizing

The design for the Bodine Hall utilizes a stand-alone PV system where the electrical energy

produced by the PV array cannot always be used when it is produced. Hence for the fact that

there is no exact match between the energy demand and the energy produced, this implies

that electrical power is being applied with the battery bank serving as a storage facility.

Therefore, the following factors were taken into consideration while sizing the battery for

this design :

Efficiency of the battery

Allowable Depth of Discharge

Days with no sunshine

The estimated number of days without sunlight was taken to be 3 days in order to achieve an

efficient battery sizing.

Therefore, Battery Capacity = Daily Load/ Battery Efficiency

= 3402/0.85= 4002 watt Hours



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Multiplying by 3 no sun days = 4002*3 = 12kWhrs

Multiplying by 80% depth of discharge

Then the battery capacity = 12kwhrs * 0.8 = 9.6KWhrs

However, batteries are usually rated in amp-hours

Amp-hours = watt-hours/volt = 9600/12= 800Ah

3. Tilt Angle of the PV Module :

The solar module has to be installed at a tilt angle approximately equal to the latitude of the

area ( BODINE HALL in Bridgeport, Connecticut as used in this project ).The tilt angle

is determined by the latitude angle for the Bridgeport CT should be about 41 deg. This

implies that the module was tilted at angle 41degree facing the east.

Therefore, the tilt angle = Latitude – 2.5degree = 38.5 degree (For Winter and Autumn)

4. Effect of Shading :

The PV should be installed where it cannot be affected by the effects of shade from nearby

buildings and trees. It is recommended that the PV System be installed on rooftops in order

to minimize the effects of shading from the buildings and trees.

5. Compressor working graph



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1. Check Valves

2. Hydraulic Inlet Check Valve

3. Hydraulic Pistons

4. Hydraulic Overpump Valves

5. Overpump Sight Glass

6. Hydraulic Injection Pump [4]

6. The change in enthalpy of the gas:

W = cp (T2 − T1) m [1]

“m” is the mass of gas compressed. The isentropic work done is

W = cp (T2’− T1) m [1]

7. Air Exit Flow Rate

[1]

[1]

8. Dimension of major equipment

Solar panel : 1.5m x 2m = 3m2

Electrolyzer: 0.92m x 1.14m = 1.0488m2

Tank: 4.58m x 1.05m = 4.809m2



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References

[1] James, Larminie, & Andrew, Dicks, (2003). Fuel cell system explained [Second Edition].

[2] N., Takano, Y, Miura, & M., Kudo. (2002). Plc based process control (PBPC) application

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[3] Retrieved from http://hansontank.us/propanetanks.html (2002-2011)

[4]Retrieved from

http://www.haskel.com/corp/details/0,10294,CLI1_DIV139_ETI10610,00.html

(2005)

[5] Retrieved from http://www.censtar.com/en/Pro_Info.aspx?ProID=48 (2006-2007)

[6] Karl , Burkart. (2010, July 17). How much co2 does one solar panel create? Retrieved

from http://www.mnn.com/green-tech/research-innovations/blogs/how-much-co2-does-one

-solar-panel-create

[7] Malcolm A, Weiss, John B., Heywood, Elisabeth M., Drake, Andreas, Schafer, & Felix F.,

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[8] Wang, Michael. (2008). Fuel-cycle analysis of hydrogen-powered fuel-cell systems with

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pdfs/fuel cycle comparison forklifts presentation.pdf

[9] Don B. Nelson, & M. Hashem Nehrir. (2005). Economic evaluation of grid-connected

fuel-cell systems. 20, 484.

[10] Retrieved from http://www.ctwater.com/newcustomer_cryssched.htm (2010)

[11] Lopes, F.C. (2009). Experimental and the cortical development of a pem electrolyzer

model applied to energy storage systems. Manuscript submitted for publication, electrical

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[12] Google map

[13] NASA, National Aeronautics and Space . (2005). Safety standard for hydrogen and

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Mission Assurance.

[14] Hydrogen/fuel cell codes and standard. (n.d.). Retrieved from

http://www.fuelcellstandards.com



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[15] Baltus, C.W.A. (1997). Analytical monitoring of losses in pv systems. Proceedings of the

European photovoltaic solar energy conference (pp. 8). Barcelona: Spain.

[16]http://www.solarpanelsplus.com/solar-calculator/

Components for your Solar Panel (Photovoltaic) Systemwritten by Kristen Hagerty & James

Cormican. Accessed December 27, 2010

[17]http://www.affordable-solar.com/ase.300-dgf-50.300.watt.solar.panel.htm

[18]http://www.scribd.com/doc/14292809/Fuel-Cells-A-Technology-Forecast

a. Accessed January 01, 2011

[19]http://www.infinitepower.org/pdf/FactSheet-24.pdf. Accessed January 02, 2011.


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